P- Grey & Ductile Iron Castings

Goal

To achieve cost-effective green sand optimization by reducing additive and new sand consumption without compromising casting quality, peel-off characteristics, or mould collapsibility

Outcome

• Bentonite consumption reduced by 22% (138.3 to 107.8 kg/LMT).
• LCA consumption reduced by 52% (48 to 22.8 kg/LMT), with additive dosage cut from 0.36% to 0.20±0.02% (a 44% reduction).
• New sand consumption reduced by 42% (363.1 to 208.8 kg/LMT); fresh silica sand addition reduced from 70 kg to 40 kg per batch.
• Improved casting surface finish and better sand peel-off, while maintaining stable green sand parameters.

Net result: additive cost saving of ₹608.9 per MT of liquid metal poured — Lustron P recommended for regular production.